future of manufacturing - driving the digital enterprise · manufacturing is getting more and more...

© Siemens Ltd. Seoul 2014. All rights reserved

Future of Manufacturing

- Driving the Digital Enterprise18th of March, 2015 Günther Klopsch

Head of Digital Factory Division

and Process Industries & Drives Division

Siemens Ltd. Seoul


Automation is one of the most efficient means to manage the limited natural

resources of this world for the continuously growing population

The growing population and the rise in the standard of

living cause a continuously growing need for all kinds of products


The Internet is revolutionizing the business world

and creates major challenges for manufacturing companies


The global challenges



Korea into the top ranks of global manufacturing

Manufacturing output continues to grow by about 2.7 percent annually in advanced economies and 7.4 percent in large developing countries

(between 2000 and 2007)

South Korea’s economy has risen steadily in global manufacturing, ranked 11th in 1990, 8th in 2000 and 7th in 2010.

South Korea’s manufacturing share of GDP is 28% ranked in the world’s 2nd place.

Manufacturing share of GDP in percentRanking by share of manufacturing gross value added

1980 1990 2000 2010Average 17

Source: McKinsey Global Institute, IHS Global Insight, United Nations Statistics Division, BEA (Nov., 2012)


Manufacturing is getting more and more important all around the world

Reform of

industrial policy

• Focus on IT integration

in industrial processes

• Energy efficiency

legislation

High-tech strategy

• Projects for the future

"Industrie 4.0" and

"Smart Services World"

Governments are launching initiatives to strengthen industry

Manufacturing

Renaissance

• Formation of a

"National Network for

Manufacturing Innovation"

• Research Center "Digital

Manufacturing and Design

Innovation"

Creative Economy

• Manufacturing Industry

Innovation 3.0 Strategy

• Plan to establish 10,000

Smart Factories by 2020


Challenges for industry are growing worldwide

Shorter innovation cycles

More complex products

Larger data volumes

Individualized mass production

Volatile markets

High productivity

Energy and resource efficiency are

decisive factors of competitiveness

Increasing competitiveness

Increase efficiency Shorten time-to-market Enhance flexibility321

Manufacturing is changing faster than ever before


Siemens Electronics Factory Amberg –

Increased productivity and energy efficiency through Plant Data Services

• At a glance: Automatically updated consumption values for

electricity, gas, water and other resources on the factory or

site level

• Reduction of energy consumption on machine level: Savings

in Christmas time of ~200,000 kWh (vs. previous year)

• Identification of unnecessary resource input in non-production

times: Annual savings of 100,000 liters liquid nitrogen

Energy Analytics –

Intelligent reports and dashboards





Larger data volumes


Volatile markets

High productivity







Big Data – Data is growing exponentially

Source: IDC's Digital Universe Study, sponsered by EMC, December 2012

Exabytes

The digital universe will reach

40 zetabyte by 2020, resulting

in a 50-fold growth from the beginning

of 2010.

2010 2020

10.000

20.000

30.000

40.000

2000

Up to the year 2000, the world generated

appr. 2 exabytes of new information:

2.000.000.000.000.000.000.

Product development Product data of one camera increased from

1.8 terabytes to 296 terabytes

2015

2.000

Today, this amount is generated in

one single day.





Larger data volumes


Volatile markets

High productivity







Increasing complexity and product variety –

For example automotive industry

Engines 11

Gears 3

Bodypanels 2

Chassis 4

Tire/rim combinations 10

Colors 45

Multimedia systems 11

Phone options 6

Assistance systems 15

Other selectable options 43

Configuration options VW Golf

Source: Volkswagen Configurator VW Golf, 1)estimated

Several trillion possible combinations1)


The way to Industrie 4.0



Setting the pace for the next industrial "revolution"

1st Industrial revolution

Introduction of mechanicalproduction plants using water and steam power

2nd Industrial revolution

Introduction of mass production based on the division of labor using electricalenergy

3rd Industrial revolution

Introduction of electronics and ITto increase the level of automation

4th Industrial revolution

Introduction of cyber-physical systemsEnd of 18th century

End of 19th century

1970

2010

Mechanical loom

Siemens single-phase generator

Industrie 4.0

Programmable Logic

Controller


The answer for the future of manufacturing –

Covering the entire product development and production process

Verify design and manufacturing processes virtually – validate and optimize real production

Productionengineering

3TIA Portal

Productionplanning 2

Teamcenter

Productdesign 1

NX

Productionexecution

4Integrated

Drive Systems

Services

5Energy

Analytics


Example: Manufacturing industry

Consistency throughout the entire value added chain

ServicesProduction designProductionplanning

Productdesign


Totally Integrated AutomationPLM Software


Real and virtual worlds are converging thanks

to innovative software and powerful hardware

Virtualworld

Realworld


“Digital Enterprise” Software Suite –

The Siemens answer to Industrie 4.0 requirements


Our automation offering

for the manufacturing industry

PLM

TECNOMATIX

Digital

Manufacturing

TEAMCENTER

Collaborative

PDM

NX

Product

Development

SIMATICHMI

SIMATICControllers

SIMATIC IDENTIndustrial Identification

SIMATIC Distributed I/O

SINAMICSDrive Systems

SIMATIC WinCC

SCADA System

SIMATIC NETIndustrial

Communication SIRIUSIndustrial Controls

SINUMERIKCNC

SIMOTIONMotion Control

TIA PORTAL

Engineering

Framework for

Automation Tasks

SIMATIC IT Production

Suite SIMATIC IT

Intelligence

Suite

Field level

Control level

Enterprise level

Management level

Operator level

ERP PLM

MES

SCADA


Faster Product design and Production planning

through PLM software


3Productionplanning 2Product

design 1NX

Productionexecution

4Services

5

Virtual Development &

Planning with PLM Software

Reduced development times


Today’s Product Challenges are

More Difficult Than Ever Before…

Landing on Mars

is one of the hardest

jobs on Earth.

On August 5, 2013, the Mars rover Curiosity landed successfully on

the surface of Mars. There was only one chance to get it right. For

this unprecedented challenge, NASA employed Siemens PLM

software solutions. The development team at NASA’s Jet

Propulsion Laboratory digitally designed, tested, assembled, and

simulated the entire Mars rover before a single physical prototype

was created.


Faster Product design and Production planning

through PLM software


3Productionplanning 2

TEAMCENTER and

TECNOMATIX

Productdesign 1

Productionexecution

4Services

5

Complete Simulation &

Optimized Production

Up to 50% reduced

time to market


Where are we today in production planning and simulation?

• Starting with the product specific data

• The production process is planned i.e. welding points

are defined

• Production equipment planning from a predefined

library

• Process optimization i.e. robot movements are

simulated

• Tool design and validation

• Virtual commissioning based on the real automation

application software

Body shop: From product data to commissioning


Cost savings through highest efficiency in production engineering


TIA Portal

Productionplanning 2Product

design 1

Productionexecution

4Services

53

Smooth Communication

of all components

Integration of all Automation Functions


Totally Integrated Automation Portal

Engineering framework for all automation tasks

One Engineering Framework

for all new Hardware components

TIA Portal

intuitive efficient proven

SINAMICS

SIMATIC HMI

SIMATIC NET

SIMATIC Controller

Safety Integrated

Distributed I/O


Efficient engineering is crucial for successful automation

TIA Portal and new portfolio make the difference in Automation

1979 1996 2010 2012 2020

Totally Integrated Automation minimizes engineering time and reduces costs –

Through efficient interoperability of all automation components

Cost of engineering Complexity of automation Total automation costs

The TIA Portal isthe key for engineering efficiency

Engineering Efficiency

Engineering cost/hour

Automation complexity (time)

Total costs

Long-term development of automation costs


Efficient Production based on one high performance network technology



design 1

Productionexecution

4Integrated

Drive Systems

Services

5

Fully integrated

Product & System Portfolio

Data integration from

shop-floor to top-floor


Energy consumption levels

in a body storage application

64% Energy saving

Calculated on a yearly production:

- 10 scissors lifts and 8 carriages

- 60s cycle time

- 250 production days

Reduction by feeding

back

10,67 MWh

New total

Energy consumption

5,89 MWh

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

Jan Feb März April Mai Juni Juli Aug Sep Okt Nov Dez

kWh

Zeit

Energy consumption without

feeding back

16,56 MWh


Services throughout the lifecycle build upon the data base of previous

process steps



design 1

Productionexecution

4Services

5Energy

Analytics

Services throughout the lifecycleThe Key to

Customer Satisfaction


Data-Driven Services based on production data:

Reduce Service, maintenance and energy costs

Customer

Operation Center

Data collector


What has to be done



From serial to parallel processes

Common data model with consistent data

flows

PLM-Team collaboration and roundtrip

engineering

Faster from idea

to production…

Solution: Integrated Workflow from Product Design to Production

….based on integration of product-

and production design

Serial Process Parallel Process

Local

optimization

Integrated

optimization

time time


Static Production Flexible ProductionIncreasing flexibility of

production…

…. based on modular production

units

From static to flexible production

Pre-defined production

process

Self optimizing

and autonomous

Solution: Use of Cyber-Physical Systems

Increase flexibility and reduce complexity

CPS

Intelligent, autonomous and self configuration/optimizing

Communicative and collaborative

Context aware


Integrated industrial cyber security protection


Our perspective of Industrie 4.0

What needs to be done!

Future: Industrie 4.0

Dynamic network of local controls

Extended complex communication

Digital models of the overall

process and participants

Process optimization in dynamic networks

Self-configuring security concepts

also for temporary requirements

Humans to define rules and frameworks

for decision making

Today: Industrie 3.8

Local controls

Realtime communication

Digital "copies" of products and production

Manufacturing Execution Systems

Industrial security concepts

Execution and decision making

mainly by humans

• Rule framework and

architecture for dynamic

topologies

• Integrated process simulation

• …

Today: Industrie 3.x

Future: Industrie 4.0


Future of Manufacturing – Prepare for change!

Look for strong

partnerships1Train your

employees3Strengthen

R&D2


Thank you for your attention!

future of manufacturing - driving the digital enterprise · manufacturing is getting more and more...

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